Cooling multiple high-density network pluggable optical modules using a shared heat exchanger

ABSTRACT

A module for multiple network pluggable optics is disclosed. The module includes a faceplate, a plurality of cage assemblies, and a plurality of springs. The faceplate includes a front face, a first wall extending from the front face, the first wall including a heat exchanger, and a second wall extending from the front face, the second wall being offset from the first wall. The plurality of cage assemblies is positioned at least partially within a volume defined by the front face and the first and second walls. Each cage assembly is configured to receive a pluggable optical module. The plurality of springs are configured with one or more springs positioned between each cage assembly and the second wall to push the plurality of cage assemblies towards the first wall such that each pluggable optical module received into one of the plurality of cage assemblies is pressed against the heat exchanger.

FIELD OF THE DISCLOSURE

The present disclosure generally relates to networking hardware. Moreparticularly, the present disclosure relates to systems and methods forcooling multiple high-density network pluggable optical modules using ashared heat exchanger, such as a shared heatsink or cold plate.

BACKGROUND OF THE DISCLOSURE

Networks, data centers, cloud computing, and the like continues to grow.Equipment manufacturers must continue to deliver substantial continuousreductions in per-bit metrics related to cost, space, and power.Telecommunication, data communication, high-performance computing, andthe like systems are typically deployed in physical hardware shelves,chassis, rack-mounted units (“pizza boxes”), cabinets, etc. that aremounted in racks or frames, freestanding, or the like. For example,typical racks or frames are either 19, 21, or 23 inches in practice.Various standards associated with racks or frames are described byTelecordia's GR-63-CORE, “NEBS Requirements: Physical Protection” (April2012), European Telecoms Standards Institute (ETSI), American NationalStandard Institute (ANSI), etc. One downside to the continualimprovement in the per-bit metrics is the increased heat, i.e., powerdissipation, and the corresponding cooling requirements (such asspecified in the NEBS standards, note NEBS stands for NetworkEquipment-Building System). Even further, network operators want todeploy frames in data centers, telecom central offices, etc. as denselyas possible, even further limiting cooling techniques, i.e.,constraining airflow between the front and back.

In optical communications equipment, it is getting increasingly harderto cool the pluggable devices. In many situations, an array of pluggableoptics ports (e.g., pluggable optical module cages) exists which canaccomplish different transmission rates. Some pluggable ports cansupport a range of rates. For example, in a situation where these portscan achieve either 100 Gb/s, 200 Gb/s, or 400 Gb/s, the heat generatedby each optical plug generally increases with transmission rate andtransmission reach. For instance, one can achieve 400 Gb/s totaltransmission with a single port or with 2×200 Gb/s ports, or 4×100 Gb/sports.

In current applications each pluggable optical module has an individualheatsink per pluggable module cage. The heatsink is biased toward thepluggable optical module which is inserted in the cage to remove anygaps created by production and assembly tolerances. The area for theheatsink may be limited by the density of the pluggable module cages. Inmany situations when higher transmission rates are used on the port,adjacent ports may not need to be populated. However, due to theindividual heatsink configuration, the ports with higher transmissionrates may not effectively utilize the heatsinks of the adjacent portsfor further cooling.

BRIEF SUMMARY OF THE DISCLOSURE

In an embodiment, a module for multiple network pluggable opticsincludes a faceplate including a front face, a first wall extending fromthe front face, the first wall including a heat exchanger, and a secondwall extending from the front face, the second wall being offset fromthe first wall; a plurality of cage assemblies positioned at leastpartially within a volume defined by the front face, the first wall andthe second wall, each cage assembly is configured to receive a pluggableoptical module; and a plurality of springs with one or more springspositioned between each cage assembly and the second wall, wherein theplurality of springs are configured to push the plurality of cageassemblies towards the first wall such that each pluggable opticalmodule received into one of the plurality of cage assemblies is pressedagainst the heat exchanger. Each cage assembly can include a cageprinted circuit board; and a cage configured to receive the pluggableoptical module, the cage being connected to the cage printed circuitboard.

The module can further include a main printed circuit board, wherein thecage printed circuit board of each cage assembly is electronicallyconnected to the main printed circuit board, and each cage printedcircuit board is sized such that a gap is formed between adjacent cageprinted circuit boards and between the cage printed circuit board of thecage assembly laterally adjacent to the main circuit board. The cageprinted circuit board of each cage assembly can be connected to the mainprinted circuit board via a rigid flex portion that is a printed circuitboard that is thinner than the main printed circuit board and the cageprinted circuit board. The faceplate can include a cutout and a gasketpositioned within the cutout for each cage assembly. The heat exchangercan include one of a cooling plate and a heatsink with a plurality offins. The faceplate can include a hook and a protrusion that engages aback of a cage assembly, the hook and protrusion being configured topress the cage assembly towards the front face.

Each cage assembly can include a cage with a cutout that is positionedadjacent to the heat exchanger, wherein the cutout is configured suchthat a contact surface of each pluggable optical module received intoone of the plurality of cage assemblies is exposed to a mating surfaceof the heat exchanger by each cutout allowing thermal contact betweenthe contact surface of each pluggable optical module and the matingsurface of the heat exchanger. The first wall can include a recessadjacent to the front face, the recess being configured to receive aportion of a flange of the cage assembly. The first wall can includechamfer at least partially facing the front face which is configured toact as a ramp to guide an end of a pluggable optical module into a cageof the cage assembly. The module can further include a pluggableheatsink sized to match a width and a height of the pluggable opticalmodule and configured to be received by each of the plurality of cageassemblies and pressed against the heat exchanger, the pluggableheatsink includes one or more channels extending therethrough that areconfigured for cooling air to pass through the pluggable heatsink andthat are sized to attenuate electromagnetic signals exiting or enteringthe cage, and an air filter positioned upstream of the one or morechannels configured to filter cooling air that enters the one or morechannels.

In another embodiment, a method for cooling multiple network pluggableoptics includes providing a faceplate including a front face, a firstwall extending from the front face, the first wall including a heatexchanger, and a second wall extending from the front face, the secondwall being offset from the first wall; providing a plurality of cageassemblies positioned at least partially within a volume defined by thefront face, the first wall and the second wall, each cage assembly isconfigured to receive a pluggable optical module; providing a pluralityof springs with one or more springs positioned between each cageassembly and the second wall; and pushing each of the plurality of cageassemblies towards the first wall with the plurality of springs suchthat each pluggable optical module received into one of the plurality ofcage assemblies is pressed against the heat exchanger.

Each cage assembly can be provided to include a cage printed circuitboard, and a cage configured to receive the pluggable optical module,the cage being connected to the cage printed circuit board. The modulecan include a main printed circuit board, and the cage printed circuitboard of each cage assembly is electronically connected to the mainprinted circuit board, the method can further include configuring eachcage assembly such that a gap is formed between adjacent cage printedcircuit boards and between the cage printed circuit board of the cageassembly laterally adjacent to the main circuit board. The faceplate caninclude a hook and a protrusion, and the method can include pushing acage assembly into the volume until the protrusion engages a back of thecage assembly. Each cage assembly can include a cage with a cutout thatis positioned adjacent to the heat exchanger, the method can furtherinclude inserting a pluggable optical module into the cage such that acontact surface of each pluggable optical module received into the cageis exposed to a mating surface of the heat exchanger by the cutoutallowing thermal contact between the contact surface of the pluggableoptical module and the mating surface of the heat exchanger. The firstwall can include chamfer at least partially facing the front face, themethod can further include inserting a pluggable optical module into acage of the cage assembly with an end of the pluggable optical modulebeing guided by the chamfer which acts as a ramp to guide the end ofeach pluggable optical module into the cage.

In a further embodiment, a faceplate of a module for multiple networkpluggable optics includes a front face; a first wall extending from thefront face, the first wall including a heat exchanger integratedtherein; and a second wall extending from the front face parallel to thefirst wall, the second wall being offset from the first wall, whereinthe front face, the first wall, and the second wall form a volumeconfigured to hold a plurality of cage assemblies between the first walland the second wall such that multiple pluggable optical modulesreceived into the plurality of cage assemblies are in thermal contactwith heat exchanger, and the second wall is configured to oppose aspring force that pushes the cage assemblies toward the heat exchanger.The faceplate can further include a plurality of cutouts in the frontface, and a gasket positioned within each of the plurality of cutouts,each of the plurality of cutouts configured to be aligned with one ofthe plurality of cage assemblies. The first wall can include a recessadjacent to the front face and a chamfer opposite the front facerelative to the recess, the recess being a configured to receive aportion of a flange of the cage assembly, and the chamfer configured toact as a ramp to guide an end of a pluggable optical module into a cageof a cage assembly.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure is illustrated and described herein withreference to the various drawings, in which like reference numbers areused to denote like system components/method steps, as appropriate, andin which:

FIGS. 1-4 are various perspective diagrams of a platform. FIG. 1 is afront perspective diagram of the platform, FIG. 2 is a front view of theplatform, FIG. 3 is a rear perspective diagram of the platform, and FIG.4 is an internal cross-sectional diagram of the platform.

FIG. 5 is a perspective diagram of a module with multiple cageassemblies and a shared heat exchanger for multiple pluggable opticalmodules, and of multiple pluggable optical modules.

FIG. 6 is a cross-sectional diagram of the module, and a pluggableoptical module of FIG. 5.

FIG. 7 is a front perspective diagram of the module of FIG. 5.

FIG. 8 is a top perspective diagram of the module of FIG. 5 with thefaceplate and the heat exchanger removed.

FIG. 9 is a top perspective diagram of the module of FIG. 5 with afloating Printed Circuit Board (PCB) for each cage and with thefaceplate and the heat exchanger removed.

FIG. 10 is the top perspective diagram of the module of FIG. 8 includingthe faceplate.

FIG. 11 is a top perspective diagram of a cage assembly.

FIG. 12 is a front perspective diagram of the cage assembly of FIG. 11.

FIG. 13 is a side perspective diagram of the cage assembly of FIG. 11.

FIG. 14 is a perspective diagram of the faceplate including the heatexchanger and multiple cage assemblies inserted therein.

FIG. 15 is a side perspective diagram of the faceplate and heatexchanger of FIG. 14.

FIG. 16 is a perspective diagram of a module with multiple rows, andmultiple pluggable optical modules.

FIG. 17 is a side perspective diagram of the faceplate of FIG. 16.

FIG. 18 is a perspective diagram of a module with multiple rows, andmultiple pluggable optical modules.

FIG. 19 is a side perspective diagram of the faceplate of FIG. 18.

FIG. 20 is a perspective diagram of a module with multiple rows, andmultiple pluggable optical modules configured for liquid cooling.

FIG. 21 is a side perspective diagram of the faceplate of FIG. 20.

FIGS. 22 and 23 are side perspective diagrams of assembly of a module.

FIG. 24 is a perspective diagram of a module, and FIG. 25 is a detailedperspective diagram of a portion of the module of FIG. 24.

FIG. 26 is a side perspective diagram of a module with a pluggableoptical module inserted therein.

FIG. 27 is a perspective diagram of a module with a shared heatexchanger for multiple pluggable optical modules, and with pluggableheat sinks.

FIG. 28 is a perspective diagram of a pluggable heat sink.

FIG. 29 is a side perspective diagram of the pluggable heat sink of FIG.28.

FIG. 30 is a bottom perspective diagram of the pluggable heat sink ofFIG. 28.

FIG. 31 is a cross-sectional diagram of the pluggable heat sink of FIG.28.

FIG. 32 is a perspective diagram of the pluggable heat sink of FIG. 28with a removable filter.

FIG. 33 is a bottom perspective diagram of the pluggable heat sink ofFIG. 32.

FIG. 34 is a cross-sectional diagram of the module and a pluggable heatsink of FIG. 27.

DETAILED DESCRIPTION OF THE DISCLOSURE

The present disclosure relates to systems and methods for coolingmultiple high-density network pluggable optical modules using a sharedheat exchanger. The present disclosure uses a module with a faceplatewith a heat exchanger that is configured to cool multiple pluggableoptics. Each pluggable optic is held in the module by a cage assemblythat includes a cage for holding the pluggable optic and a cage PCB thatis connected to a main PCB. The cage assembly and the pluggable opticare pressed toward the heat exchanger by one or more springs positionedbetween the cage PCB and an opposing wall that extends from a front faceof the faceplate parallel to the heat exchanger.

By pressing the cage assembly and pluggable optic towards the heatexchanger connected or integrated into the faceplate, any gaps presentdue to tolerances of the components of the cage assembly, faceplate, andpluggable optic can be avoided to ensure that there is thermal contactbetween the surfaces of the pluggable optic and the heat exchanger andto minimize thermal resistance between the pluggable optic and the heatexchanger.

For a finned heat exchanger, the shared heat exchanger allows for asignificant increase in the finned area interfacing with cooling air toimprove cooling. For a liquid cooled heat exchanger, a single coolingline can be used for the shared heat exchanger, which can reduce thecomplexity of the cooling configurations, such as by reducing the numberof connections, manifolds, and the like to supply the cooling liquid tothe heat exchanger.

Sometimes a circuit pack has space allocation for many differentpluggable optics operating at different rates, where higher rate andhigher reach pluggable optic dissipate more power. If the use of higherrate pluggable optics eliminates the need for its neighboring pluggableoptic to avoid oversubscribing the bandwidth of the circuit pack, thenthat port will remain empty, but capped at the faceplate with a standarddust cap. In this case the area of the heat exchanger from the emptyneighbor can be used to cool the hotter pluggable optic, where it couldnot otherwise be cooled with the heat exchanger space available.

Also, the present disclosure utilizes various terms in the art such asmodule and card. Those of ordinary skill in the art will recognize theseterms may be used interchangeably. Further, these do not requireremovability. That is, a module or card may be fixed in a platform. Onthe other hand, an interface card or a pluggable module (again theseterms may be used interchangeably) is selectively removable from a cage,slot, etc. in the platform. Also, the term platform is used herein todenote a hardware device housing the modules or cards. The platform mayinclude a shelf, chassis, rack-mounted unit, “pizza box,” etc.

FIGS. 1-4 are various perspective diagrams of a platform 100. FIG. 1 isa front perspective diagram of the platform 100, FIG. 2 is a front viewof the platform 100, FIG. 3 is a rear perspective diagram of theplatform 100, and FIG. 4 is an internal cross-sectional diagram of theplatform 100. FIGS. 1-4 are from commonly-assigned U.S. Pat. No.9,769,959, issued Sep. 19, 2017, and entitled “HIGH DENSITY NETWORKINGSHELF AND SYSTEM,” the contents of which are incorporated herein byreference. The platform 100 can be a shelf, a system, etc. forming anetwork element, a node, etc. in a network. The platform 100 can includefront and rear air intake/exhaust without side ventilation, therebymaintaining NEBS compliance. Additionally, the platform 100 is ahalf-rack system that is scalable to a double (full rack) sized system.The platform 100 is presented as an example for illustration purposes.Those skilled in the art will recognize other physical embodiments arecontemplated. That is, the present disclosure contemplates use with anyhardware platform having pluggable modules.

In an embodiment, the platform 100 can be a network element that mayconsolidate the functionality of a Multi-Service Provisioning Platform(MSPP), Digital Cross-Connect (DCS), Ethernet and/or Optical TransportNetwork (OTN) switch, Dense Wave Division Multiplexing (DWDM) platform,etc. into a single, high-capacity intelligent switching system providingLayer 0, 1, and 2 consolidation. In another exemplary embodiment, theplatform 100 can be any of an OTN Add/Drop Multiplexer (ADM), aSONET/SDH/OTN ADM, a MSPP, a DCS, an optical cross-connect, an opticalswitch, a router, a switch, a DWDM terminal, wireless backhaul terminal,an access/aggregation device, etc. That is, the platform 100 can be anydigital and/or optical system with ingress and egress signals andswitching therebetween of channels, timeslots, tributary units, packets,etc. utilizing OTN, SONET, SDH, Ethernet, IP, etc. In anotherembodiment, the platform 100 can be a high-rate Ethernet switch. In afurther embodiment, the platform 100 can be a DWDM terminal. In yetanother embodiment, the platform 100 can be a compute, wireless,storage, or another type of hardware platform. The key aspect of theplatform 100 with the present disclosure and any other platform are thefront faceplate openings, via interface cards 114 in a cage.

The platform 100 includes a housing 102 which can refer to any shelf,rack, cabinet, case, frame, chassis, or other apparatus used to arrangeand/or support a plurality of electronic/optical components such asremovable cards, including modules with interface cards 114 and switchfabric cards 116. The housing 102 may be metal, plastic, or combination,or other suitable material and similar in construction to otherhousings, cabinets and/or racks used to hold electronic/opticalcomponents in place. Further, the housing 102 may be rack mounted in anETSI, ANSI, etc. compliant rack or frame, as well as being deployed in acabinet, etc. The housing 102 has a front side 104, a rear side 106opposite the front side 104, a right side 108 adjacent to both the frontside 104 and the rear side 106, and a left side 110 opposite the rightside and adjacent to both the front side 104 and the rear side 106.Airflow in the platform 100 is between the front side 104 and the rearside 106; there may be no airflow through or between the sides 108, 110.

The housing 102 supports a set of interface cards 114 and, optionally, aset of switch fabric cards 116. The interface cards 114 are arranged ina first direction 120. The switch fabric cards 116 are arrangedsubstantially orthogonally, i.e., perpendicular, to the first direction120. In this embodiment, the interface cards 114 are vertically aligned,and the switch fabric cards 116 are horizontally aligned. The cards 114,116 may optionally be surrounded by a separate metallic Faraday Cageincluding, for example, a metal mesh screen. The orthogonal arrangementof the switch fabric cards 116 as compared with the interface cards 114can form a recessed portion.

The interface cards 114 can include selectively inserted pluggableoptical transceivers (can also be called pluggable electro-opticaltransceivers_. Again, the interface cards 114 can be referred to as linecards, line blades, I/O modules, etc. and can include a plurality ofoptical modules in the front. For example, the optical modules can bepluggable modules such as, without limitation, XFP, SFP, XENPAK, X2,CFP, CFP2, CFP4, QSFP, QSFP+, QSFP28, OSFP, QSFP-DD, and the like.Further, the interface cards 114 can include a plurality of opticalconnections per module. The interface cards 114 can include wavelengthdivision multiplexing interfaces, short-reach interfaces, and the like,and can connect to other interface cards 114 on remote network elements,end clients, edge routers, and the like.

From a logical perspective, the interface cards 114 provide ingress andegress ports to the platform 100, and each interface card 114 caninclude one or more physical ports. The optional switch fabric cards 116are configured to switch channels, timeslots, tributary units, packets,cells, etc. between the interface cards 114. The interface cards 114and/or the switch fabric cards 116 can include redundancy as well, suchas 1:1, 1:N, etc. In an embodiment, the high-density platform 100 can be15-16RU with 12 slots for line modules housing the interface cards 114and 4 slots for the switch fabric cards 116. Here, the high-densityplatform 100 with a circuit pack of twelve can dissipate between 600-750W. Further, the switch fabric cards 116 can be single fabric or doublefabric (with additional pins to the backplane from the single fabric).Additionally, the platform 100 contemplates operation in an ETSI, ANSI,19″, or 23″ rack or frame.

The platform 100 can include common equipment 130, power connections132, and a fiber manager 134. The common equipment 130 is utilized forOperations, Administration, Maintenance, and Provisioning (OAM&P)access; user interface ports; and the like. The platform 100 can includean interface for communicatively coupling the common equipment 130, theinterface cards 114, and the switch fabric cards 116 therebetween. Forexample, the interface can be a backplane, midplane, a bus, optical orelectrical connectors, or the like. The interface cards 114 areconfigured to provide ingress and egress to the platform 100.

Those of ordinary skill in the art will recognize the platform 100 caninclude other components which are omitted for illustration purposes,and that the systems and methods described herein are contemplated foruse with a plurality of different network elements with the platform 100presented as an example type of network device or hardware platform. Forthe high-density platform 100, other architectures providing ingress,egress, and switching therebetween are also contemplated for the systemsand methods described herein. Those of ordinary skill in the art willrecognize the systems and methods can be used for practically any typeof network device which includes interface cards 114 on the frontfaceplate.

The platform 100 includes a housing with a front side, a rear sideopposite the front side, a right side adjacent to both the front sideand the rear side, and a left side opposite the right side and adjacentto both the front side and the rear side. One or more modules in thehousing each including a plurality of cages supporting removableinterface cards. The removable interface cards can be pluggable opticalmodules.

FIG. 5 is a perspective diagram of a module 300 with multiple cageassemblies 330 and a shared heat exchanger 350 for multiple pluggableoptical modules 50, and of multiple pluggable optical modules 50, FIG. 6is a cross-sectional diagram of the module 300, and a pluggable opticalmodule 50 of FIG. 5, and FIG. 7 is a front perspective diagram of themodule 300 of FIG. 5.

As can be seen in FIGS. 5-7, the module 300 includes a faceplate 310,multiple cage assemblies 330, springs 380, a shared heat exchanger 350,a main PCB 360, cables 370, and connectors 372. Pluggable opticalmodules 50 can be received in cages 332 of the cage assemblies 330 viaone or more openings 312 in a front face 311 of the faceplate 310. Themain PCB 360 can be affixed to the faceplate 310. The cage assemblies330 can be connected to the main PCB 360 via cables 370 with connectionends 372 that mate with connectors 374 affixed to the main PCB 360. Oneor more springs 380 are positioned between each cage assembly 330 and awall 316 of the faceplate. The one or more springs 380 bias the cageassembly 330 towards the heat exchanger 350 to press the pluggableoptical module 50 against a mating surface 354 of the heat exchanger350.

FIG. 8 is a top perspective diagram of the module 300 of FIG. 5 with thefaceplate 310 and the heat exchanger 350 removed. FIG. 9 is a topperspective diagram of the module 300 of FIG. 5 with a cage PCB 365 foreach cage 332 and with the faceplate 310 and the heat exchanger 350removed. FIG. 10 is the top perspective diagram of the module 300 ofFIG. 9 including the faceplate 310.

As can be seen in FIGS. 8-10, each cage assembly 330 includes a cage 332and a cage PCB 365. The cage 332 is affixed to the cage PCB 365. Thecable 370 can also be included in the cage assembly 330. Each cage PCB365 is sized such that the module 300 includes slots 367 positionedlaterally between adjacent cage PCBs 365 and laterally between each cagePCB 365 at an end of the array of cage assemblies 330 and the main PCB360.

As can be seen in FIGS. 6 and 8, an end of each cage PCB 365 can beconnected to the main PCB 360 via a rigid flex portion 366. The rigidflex portion 366 can be a PCB that is thinner than the main PCB 360 andthe cage PCB, and may be a portion of the main PCB 360 that is milled onone or more sides, which can allow the cage PCB 365 to move vertically(transverse to the direction of the slots) such that the cage assembly330 can be biased towards the heat exchanger 350. While high speedconnections can be made to the main PCB 360 from the cage assembly 330via cables 370, remaining signals, such as those that are low speed, cantrack to the main PCB 360 via the rigid flex portion 366.

In some embodiments, one or more of the PCBs and rigid flex portion 366can be capable of transferring hi-speeds signals therebetween, and cancomprise multiple flexible circuits attached together, such as RigidFlex PCBs. In one embodiment, the main PCB 360 and each cage PCB 365 canbe a rigid PCB, while each rigid flex portion 366 is a flexible circuitattached to the main PCB 360 and a cage PCB 365. The rigid PCBs and theflexible circuits can be integrated together into one circuit. In theseembodiments, the cables 370 can be eliminated.

As can be seen in FIGS. 9 and 10, the end of each cage PCB 365 can alsobe separated from the main PCB 360 via a slot 368, such that each cagePCB 365 is floating. Each cage PCB 365 can be aligned with respect tothe faceplate 310 with aligners 364, such as pins or shoulder screws,that mate with holes 363 that are cut into the main PCB 360 and the cagePCBs 365. At least some of the holes 363 may be formed by cutting intoadjacent sides of cage PCBs 365 or adjacent sides of a cage PCB 365 andthe main PCB 360.

FIG. 11 is a top perspective diagram of a cage assembly 330. FIG. 12 isa front perspective diagram of the cage assembly 330 of FIG. 11. FIG. 13is a side perspective diagram of the cage assembly 330 of FIG. 11.

As can be seen in FIGS. 11-13, the end of the cage PCB 365 can extendbeyond an end to the cage 332, and the cage assembly 330 can include aconnector 376 that connects the cage PCB 365 to the main PCB 360 viacables such that remaining signals, such as those that are low speed,can track to the main PCB 360. Alternatively, the end of the cage PCB365 that is floating due to the slots 368 can also be connected via arigid flex portion 366 or can be connected via a combination of theconnector 376 and a rigid flex portion 366.

The cage 332 can include a body 334 shaped to receive a pluggableoptical module 50 and that is connected to the cage PCB 365. The cage332 can also include a cutout 336 in the body 334 that cuts back a topof the cage 332, which can be opposite the cage PCB 365. The cutout 336is configured to allow for a portion of the shared heat exchanger 350 tosit therein and have continuous contact with the pluggable opticalmodule 50 received in the body 334.

The cage 332 can further include a gasket 340 positioned at an open endof the body 334. The gasket 340 can be an EMI (electromagneticinterference) type gasket. As can be seen in FIGS. 8, 9 and 12, thegasket 340 can be positioned within a flange 342 of the body 332, aspring type gasket, and the like.

FIG. 14 is a perspective diagram of the faceplate 310 including the heatexchanger 350 and multiple cage assemblies 330 inserted therein, andFIG. 15 is a side perspective diagram of the faceplate 310 and heatexchanger 350 of FIG. 14.

As can be seen in FIGS. 14 and 15, the faceplate 310 can include a frontface 311, a first wall 314 extending from the front face 311, a secondwall 316 extending from the front face 311, and a hook 320. The firstwall 314 can include a lip 313 and the heat exchanger 350. The lip 313and the heat exchanger 350 can be shaped to form a recess 315, which canbe configured to receive an upper portion of the cage 332, such as anupper portion of the flange 342. The first wall 314 can also include achamfer 317 opposite the front face 311 relative to the recess 315. Thechamfer 317 can also be adjacent a mating surface 354 of the heatexchanger 350, the mating surface 354 being configured to contact asurface of the pluggable optical module 50.

The heat exchanger 350 can be a cold plate, a heatsink, and the like. Asillustrated in FIGS. 14 and 15, the heat exchanger 350 can include fins351 or other shapes. All or portions of the heat exchanger 350 can beformed integrally with the first wall 314 or can be formed separatelyand integrally joined to the remainder of the first wall 314.

The second wall 316 can extend parallel to the first wall 314 and isoffset from the first wall 314. The front face 311, the first wall 314,and the second wall 316 form a volume 319 for receiving multiple cageassemblies 330. The second wall 316 is opposite the first wall 314relative to the volume 319.

The hook 320 is positioned opposite the front face 311 and includes aprotrusion 322 that is configured to apply a gasket force to the cage332, such as forcing the cage into a compressible gasket or to locatethe cage 332 with a spring type gasket. The hook 322 can be at an end ofthe first wall 314 and can extend from the heat exchanger 350 as shownin FIG. 15 or can be at an end of the second wall 316. The hook 322 canextend further than the opposing wall so that the protrusion 322 ispositioned further from the front face 311 than an end of the opposingwall.

The faceplate 310 can also include one or more gaskets 318 positionedwithin the one or more openings 312 in the front face 311.

The faceplate 310 can be configured to receive a single row of cageassemblies 330 and pluggable optical modules 50 or can be configured toreceive multiple rows of cage assemblies 330 and pluggable opticalmodules 50.

FIGS. 16, 18, and 20 are perspective diagrams of modules with multiplerows, multiple cage assemblies, and multiple pluggable optical modules.FIGS. 17, 19, and 21 are side perspective diagrams of the modules ofFIGS. 16, 18, and 20 respectively.

As can be seen in FIGS. 16-21, the faceplate 330 can include a thirdwall 324 and a second hook 344, which can be integral to the third wall324. The third wall can extend from the front face 311 parallel to thefirst wall 314 and the second wall 316. The third wall 324 can besymmetrical to the first wall 314 relative to the second wall 316 (suchas a mirror image of the first wall 314).

The third wall 324 can include a lip 323 and a second heat exchanger355. The lip 346 and the second heat exchanger 355 can be shaped to forma recess 325, which can be configured to receive an upper portion of thecage 332, such as an upper portion of the flange 342. The third wall 324can also include a chamfer 327 opposite the front face 311 relative tothe recess 325. The chamfer 327 can also be adjacent a mating surface356 of the second heat exchanger 355, the mating surface 356 beingconfigured to contact a surface of the pluggable optical module 50.

The front face 311, the third wall 324, and the second wall 316 form asecond volume 329 for receiving multiple cage assemblies 330. The secondwall 316 is opposite the third wall 324 relative to the volume 329.

The second hook 344 is positioned opposite the front face 311 andincludes a protrusion 346 that is configured to apply a gasket force tothe cage 332, such as forcing the cage into a compressible gasket or tolocate the cage 332 with a spring type gasket. The second hook 344 canbe at an end of the third wall 314 and can extend from the heatexchanger 350. The hook 322 can extend further than the second wall 316so that the protrusion 322 is positioned further from the front face 311than an end of the second wall 316.

The heat exchangers 350 and 355 can be a heatsink, such as a heatsinkwith a plurality of fins. The fins can extend in any direction, such astransverse to the first wall 314 and the third wall 316 (see FIGS. 16and 17) or in the same direction as the as the first wall 314 and thethird wall 316 (see FIGS. 18 and 19). The heat exchangers 350 and 355can also be a cold plate, such as a cold plate with liquid cooling. Theuse of each heat exchanger 350 and 355 to cool multiple pluggableoptical modules 50 can reduce the complexity of the coolingconfigurations. For example, a cold plate with liquid cooling that coolsmultiple pluggable optical modules 50 can significantly reduce thenumber of connections, manifolds, and the like to provide the coolingliquid to the cold plate. Other types of heat exchangers andconfigurations of heat exchangers are also contemplated.

FIGS. 22 and 23 are side perspective diagrams of assembly of a module310 and of the insertion of a cage assembly 330 into the faceplate 310.With the protrusion 322 of the hook 320 being positioned further than anend of the second wall 316, the flange 342 or any other protrudingportion of the cage 332 can easily be inserted into the volume 319passed the protrusion 322. During insertion, the one or more springs 380are compressed between the cage PCB 365 and the second wall 316, whichpushes the cage assembly 330 towards the heat exchanger 350. The cageassembly is pushed from the rear toward the gasket 318 until the cageassembly 330 clears the protrusion 322 of the hook 320, which retainsthe cage assembly 330 at least partially within the volume 319 andpresses the cage assembly toward the front face 311 and the gasket 318.Due to the configuration of the hook 320 and the protrusion 322, thecage assembly 330 can be retained in the volume 319 without anyfasteners.

The flange 342 or any other protruding portion at a front end of thecage 332 can be pressed up and received into the recess 315, and therecess 315 can be sized to receive the flange 342.

While assembly of the module 330 is described with respect to insertinga cage assembly 330 into the volume 319, inserting a cage assembly 330into the volume 329 in the same or a similar manner.

Referring to FIGS. 6, 22, and 23, the one or more springs 380 areretained between the cage PCB 365 and the second wall 316, and can beconnected to the cage PCB 365 as part of the cage assembly 330, can beconnected to the second wall 316 as part of the faceplate 310, or can bean assembly separate from both cage assembly 330 and the faceplate 310and retained in another manner. The one or more springs 380 can push offthe second wall 316 to press the cage assembly 330 and the pluggableoptical module 50 towards the heat exchanger 350 and can oppose anythermal contact spring force that is integrated or bolted to faceplate310.

FIG. 24 is a perspective diagram of a module 300, and FIG. 25 is adetailed perspective diagram of a portion of the module 300 of FIG. 24.The module 300 can include positioning clips 390. The positioning clip390 can keep the cage assembly 330 aligned with respect to the opening312 in the front face 311 of the faceplate 310.

The module 300 can include multiple hooks 320, such that there is asingle hook 320 for each cage assembly 330. The hooks 320 can be sizedsuch that there is a gap 348 between adjacent hooks 320. The positioningclip 390 can be configured to receive a hook 320 therein and to besecured to the hook 320, such as by fastening.

The positioning clip 390 can include legs 392, each with a protrudingportion 393. The legs can extend beyond the cage PCB 365 with theprotruding portions 393 clipped on an opposing side of the cage PCB 365.The positioning clip 390 can also include side walls 394 that extendalong the sides of the cage assembly 330 to position the cage assembly330. The side walls 394 can also extend along and in contact with thefirst wall 314 including along the mating surface 354 of the heatexchanger 350.

The legs 392 and protruding portions 393 can ensure that the cageassembly 330 is properly angled in the direction of the force applied bythe one or more springs 380, while the side walls 394 can ensure thatthe cage assembly 330 is properly centered and angled in a directionthat the row of cage assemblies 330 extends.

The positioning clip 390 can be similarly configured to be assembledwith the second hook 344.

FIG. 26 is a side perspective diagram of a module 300 with a pluggableoptical module 50 inserted therein. While inserting the pluggableoptical module 50, the chamfer 317 of the first wall 314 can act as aramp to guide an end of the pluggable optical module 50 into the volume319. The one or more springs 380 press against the second wall 316 andpush the cage assembly 330 toward the first wall 314, pressing a contactsurface 52 of the pluggable optical module 50 against a mating surface354 of the heat exchanger 350 to ensure that there is thermal contactbetween the surfaces and to minimize thermal resistance between thepluggable optical module 50 and the heat exchanger 350.

FIG. 27 is a perspective diagram of a module 300 with a shared heatexchanger 350 for multiple pluggable optical modules 50, and withpluggable heatsinks 60. As noted above, where a high transmission ratepluggable optical module 50 is used ports adjacent to it remain unusedand the pluggable optical module 50 can be further cooled by the sharedheat exchanger 350. The pluggable heatsinks 60 can be inserted into theempty cages 352 through the openings 312 in the faceplate 310, takingadvantage of the unused space to assist the cooling of the pluggableoptical modules 50 in occupied cages 352. Where a pluggable heatsink 60may not be required and air ingress are not necessary, a dust cap can beinserted into the unoccupied cages 352 to prevent EMI breach.

FIG. 28 is a perspective diagram of a pluggable heatsink 60. FIG. 29 isa side perspective diagram of the pluggable heatsink 60 of FIG. 28. FIG.30 is a bottom perspective diagram of the pluggable heatsink 60 of FIG.28. FIG. 31 is a cross-sectional diagram of the pluggable heatsink 60 ofFIG. 28. FIG. 32 is a perspective diagram of the pluggable heatsink 60of FIG. 28 with a removable filter. FIG. 33 is a bottom perspectivediagram of the pluggable heatsink 60 of FIG. 32. FIG. 34 is across-sectional diagram of the module 300 and pluggable heatsink 60 ofFIG. 27.

The pluggable heatsink 60 can include a body 61 and a handle 63. Thebody 61 can be sized to match the width and height of the pluggableoptical modules 50 that it replaces and can be sized to ensure there isan EMI seal. The body 61 can include a contact surface, an intake end 70that receives cooling air flowing through the platform, and an exhaustend 75 for expelling the cooling air.

The contact surface 67 can be a flat surface that is configured tocontact the mating surface 354 of the heat exchanger 350. The intake end70 can include a filter 71. The filter 71 can be removable, and can befastened or otherwise held in place, such as by a clip 79 (refer toFIGS. 32 and 33).

The exhaust end 75 can include one or more openings 78 for the coolingair to exit through. The exhaust can also include angled surfaces 76 and77, which can each include one or more openings 78. The angled surfaces76 and 77 can form a wedge shape at the exhaust end and can beconfigured to direct the cooling air at angles relative to a lengthdirection of the body 61. In particular, the one or more openings 78 ofangled surface 76 can be configured to direct cooling air at an angleaway from the contact surface 67 and the mating surface 354, while theone or more openings 78 of angled surface 77 can be configured to directcooling air at an angle in an opposing direction, towards the matingsurface 354.

The body 61 can also include grooves 65 and 66 that are adjacent theintake end 70. Groove 66 can be positioned on a top of the body 61adjacent the contact surface 67, and groove 65 can be positioned on abottom of the body 61 opposite the groove 66. The grooves 65 and 66 canbe positioned to meet an apex of the internal cage gaskets 340 (refer toFIG. 12 and FIG. 34). The grooves 65 and 66 can prevent the pluggableheatsink 60 from walking out of the cage 352.

Referring to FIG. 31, the body 61 can include one or more channelsextending therethrough. The one or more channels can include fins 73that contact the cooling air for discharging heat from the pluggableheatsink 60 to the cooling air. The fins 73 and the one or more channelscan be sized to meet both thermal requirements and to act likewaveguides in the one or more channels to attenuate electro-magneticnoise as it enters or leaves the port/cage 352. The one or more channelscan also be sized to meet thermal requirements and EMI requirements. Thebody can further include a horizontal bar 72 to make the max distance ofthe channels smaller.

The handle 63 can be formed integrally to the body 61 or can be aseparate component attached to the body 61. The handle 63 can extendfrom the intake end 70 so as to protrude outward from the faceplate 310when inserted into the module 300. The handle 63 can include a hole 64or other similar features that can assist in gripping the handle forinsertion and removal of the pluggable heatsink 60 into and out of themodule 300.

The pluggable heatsink 60 can include one or more brackets 69 furtherconnecting the handle 63 to the body 61 to strengthen the handle 63.

Referring to FIG. 34, when inserted into the module 300, the contactsurface 67 mates with the mating surface 354 of the heat exchanger 350.Similar to the pluggable optical module 50, the one or more springs 380of the cage assembly press the pluggable heatsink 60 upwards to ensurecontact between the contact surface 67 and the mating surface 354 ismaximized, thus, minimizing thermal resistance allowing the pluggableheatsink 60 to remove heat from the heat exchanger 350 via conductionand assist in cooling the pluggable optical modules 50.

The first wall 314 can have one or more cooling holes 359 that ispositioned downstream of the exhaust end of the pluggable heatsink, andwhich can be positioned in the heat exchanger 350. The cutouts 336 ofcages 332 can be sized to be open to the one or more cooling holes 359.Cooling air exiting the one or more openings 78 of angled surface 77 canbe directed towards the one or more cooling holes 359.

The cage PCB 365 can also have one or more cooling holes 369 that ispositioned downstream of the exhaust end 75 of the pluggable heatsink60. Cooling air exiting the one or more openings 78 of angled surface 76can be directed towards the one or more cooling holes 369.

While angled surfaces 76 and 77 are described herein, other surfaceconfigurations are also contemplated, such as a rounded surface withcooling holes, and the like.

A length of the pluggable heatsink 60 can be configured such that thereis a gap between the exhaust end 75 and the an optical plug connector ofthe cage 352 to ensure that the cooling air can exit the exhaust end 75and flow out of the cooling holes 359 and 369.

It will be appreciated that some embodiments described herein mayinclude or utilize one or more generic or specialized processors (“oneor more processors”) such as microprocessors; Central Processing Units(CPUs); Digital Signal Processors (DSPs): customized processors such asNetwork Processors (NPs) or Network Processing Units (NPUs), GraphicsProcessing Units (GPUs), or the like; Field-Programmable Gate Arrays(FPGAs); and the like along with unique stored program instructions(including both software and firmware) for control thereof to implement,in conjunction with certain non-processor circuits, some, most, or allof the functions of the methods and/or systems described herein.Alternatively, some or all functions may be implemented by a statemachine that has no stored program instructions, or in one or moreApplication-Specific Integrated Circuits (ASICs), in which each functionor some combinations of certain of the functions are implemented ascustom logic or circuitry. Of course, a combination of theaforementioned approaches may be used. For some of the embodimentsdescribed herein, a corresponding device in hardware and optionally withsoftware, firmware, and a combination thereof can be referred to as“circuitry configured to,” “logic configured to,” etc. perform a set ofoperations, steps, methods, processes, algorithms, functions,techniques, etc. on digital and/or analog signals as described hereinfor the various embodiments.

Moreover, some embodiments may include a non-transitorycomputer-readable medium having instructions stored thereon forprogramming a computer, server, appliance, device, processor, circuit,etc. to perform functions as described and claimed herein. Examples ofsuch non-transitory computer-readable medium include, but are notlimited to, a hard disk, an optical storage device, a magnetic storagedevice, a Read-Only Memory (ROM), a Programmable ROM (PROM), an ErasablePROM (EPROM), an Electrically EPROM (EEPROM), Flash memory, and thelike. When stored in the non-transitory computer-readable medium,software can include instructions executable by a processor or device(e.g., any type of programmable circuitry or logic) that, in response tosuch execution, cause a processor or the device to perform a set ofoperations, steps, methods, processes, algorithms, functions,techniques, etc. as described herein for the various embodiments.

Although the present disclosure has been illustrated and describedherein with reference to preferred embodiments and specific examplesthereof, it will be readily apparent to those of ordinary skill in theart that other embodiments and examples may perform similar functionsand/or achieve like results. All such equivalent embodiments andexamples are within the spirit and scope of the present disclosure, arecontemplated thereby, and are intended to be covered by the followingclaims.

What is claimed is:
 1. A module for multiple network pluggable optics,the module comprising: a faceplate including a front face, a first wallextending from the front face, the first wall including a heatexchanger, and a second wall extending from the front face, the secondwall being offset from the first wall; a plurality of cage assembliespositioned at least partially within a volume defined by the front face,the first wall and the second wall, each cage assembly is configured toreceive a pluggable optical module; and a plurality of springs with oneor more springs positioned between each cage assembly and the secondwall, wherein the plurality of springs are configured to push theplurality of cage assemblies towards the first wall such that eachpluggable optical module received into one of the plurality of cageassemblies is pressed against the heat exchanger, wherein the faceplateincludes a cutout and a gasket positioned within the cutout for eachcage assembly.
 2. The module of claim 1, wherein each cage assemblyincludes a cage printed circuit board; and a cage configured to receivethe pluggable optical module, the cage being connected to the cageprinted circuit board.
 3. The module of claim 2, further comprising amain printed circuit board, wherein the cage printed circuit board ofeach cage assembly is electronically connected to the main printedcircuit board, and each cage printed circuit board is sized such that agap is formed between adjacent cage printed circuit boards and betweenthe cage printed circuit board of the cage assembly laterally adjacentto the main circuit board.
 4. The module of claim 3, wherein the cageprinted circuit board of each cage assembly is connected to the mainprinted circuit board via a rigid flex portion that is a printed circuitboard that is thinner than the main printed circuit board and the cageprinted circuit board.
 5. The module of claim 1, wherein the heatexchanger includes one of a cooling plate and a heatsink with aplurality of fins.
 6. The module of claim 1, wherein each cage assemblyincludes a cage with a cutout that is positioned adjacent to the heatexchanger, wherein the cutout is configured such that a contact surfaceof each pluggable optical module received into one of the plurality ofcage assemblies is exposed to a mating surface of the heat exchanger byeach cutout allowing thermal contact between the contact surface of eachpluggable optical module and the mating surface of the heat exchanger.7. The module of claim 1, wherein the first wall includes a recessadjacent to the front face, the recess being configured to receive aportion of a flange of the cage assembly.
 8. The module of claim 1,wherein the first wall includes a chamfer at least partially facing thefront face which is configured to act as a ramp to guide an end of apluggable optical module into a cage of the cage assembly.
 9. The moduleof claim 1, wherein the heat exchanger allows liquid cooling.
 10. Amodule for multiple network pluggable optics, the module comprising: afaceplate including a front face, a first wall extending from the frontface, the first wall including a heat exchanger, and a second wallextending from the front face, the second wall being offset from thefirst wall; a plurality of cage assemblies positioned at least partiallywithin a volume defined by the front face, the first wall and the secondwall, each cage assembly is configured to receive a pluggable opticalmodule; and a plurality of springs with one or more springs positionedbetween each cage assembly and the second wall, wherein the plurality ofsprings are configured to push the plurality of cage assemblies towardsthe first wall such that each pluggable optical module received into oneof the plurality of cage assemblies is pressed against the heatexchanger, wherein the faceplate includes a hook and a protrusion thatengages a back of a cage assembly, the hook and protrusion beingconfigured to press the cage assembly towards the front face.
 11. Themodule of claim 10, wherein each cage assembly includes a cage printedcircuit board; and a cage configured to receive the pluggable opticalmodule, the cage being connected to the cage printed circuit board. 12.The module of claim 10, wherein the heat exchanger includes one of acooling plate and a heatsink with a plurality of fins.
 13. The module ofclaim 10, wherein each cage assembly includes a cage with a cutout thatis positioned adjacent to the heat exchanger, wherein the cutout isconfigured such that a contact surface of each pluggable optical modulereceived into one of the plurality of cage assemblies is exposed to amating surface of the heat exchanger by each cutout allowing thermalcontact between the contact surface of each pluggable optical module andthe mating surface of the heat exchanger.
 14. The module of claim 10,wherein the first wall includes a recess adjacent to the front face, therecess being configured to receive a portion of a flange of the cageassembly.
 15. The module of claim 10, wherein the first wall includes achamfer at least partially facing the front face which is configured toact as a ramp to guide an end of a pluggable optical module into a cageof the cage assembly.
 16. The module of claim 10, wherein the heatexchanger allows liquid cooling.
 17. A module for multiple networkpluggable optics, the module comprising: a faceplate including a frontface, a first wall extending from the front face, the first wallincluding a heat exchanger, and a second wall extending from the frontface, the second wall being offset from the first wall; a plurality ofcage assemblies positioned at least partially within a volume defined bythe front face, the first wall and the second wall, each cage assemblyis configured to receive a pluggable optical module, wherein each cageassembly includes a cage printed circuit board, and a cage configured toreceive the pluggable optical module, the cage being connected to thecage printed circuit board; a plurality of springs with one or moresprings positioned between each cage assembly and the second wall,wherein the plurality of springs are configured to push the plurality ofcage assemblies towards the first wall such that each pluggable opticalmodule received into one of the plurality of cage assemblies is pressedagainst the heat exchanger; and a main printed circuit board, whereinthe cage printed circuit board of each cage assembly is electronicallyconnected to the main printed circuit board, and each cage printedcircuit board is sized such that a gap is formed between adjacent cageprinted circuit boards and between the cage printed circuit board of thecage assembly laterally adjacent to the main circuit board, wherein thecage printed circuit board of each cage assembly is connected to themain printed circuit board via a rigid flex portion that is a printedcircuit board that is thinner than the main printed circuit board andthe cage printed circuit board.
 18. The module of claim 17, wherein theheat exchanger includes one of a cooling plate and a heatsink with aplurality of fins.
 19. The module of claim 17, wherein the faceplateincludes a hook and a protrusion that engages a back of a cage assembly,the hook and protrusion being configured to press the cage assemblytowards the front face.
 20. The module of claim 17, wherein the heatexchanger allows liquid cooling.